System and Method for Producing Resin Cartridges

ABSTRACT

A method is disclosed for packaging a curable resin composition and a catalyst composition that react with each other when mixed, comprising providing a partitioned tube for receiving the resin composition and the curing agent in separate compartments; delivering a stream of a resin composition into one compartment of the tube; delivering a stream of a curing agent in the other compartment of the tube; advancing the partitioned tube and constricting and sealing the partitioned tube at spaced apart intervals and severing the sealed tube to produce a package partitioning the resin composition from the catalyst composition. Solid particulate is continuously added into the stream of at least one of the catalyst composition and the resin composition and mixing the solid particulate and stream to produce a mixed composition; and the relative amount of solid particulate in the mixed composition is controlled by continuously determining the mass of solid particulate added to the mass of the stream.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.11/807,655, filed May 30, 2007, which claims the benefit of U.S.Provisional Patent Application No. 60/861,510, filed Nov. 29, 2006, andboth entitled “System and Method for Producing Resin Cartridges”, all ofwhich are incorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to a system and method for producingpartitioned tubular film packages that retain different materials oneither side of a partition, and more particularly, to a method ofproducing mine roof bolt resin packages in which a polymerizable resincomponent and a catalyst component are retained on opposing sides of apartition in a tubular package.

2. Description of Related Art

Mine roof bolts and other structural elements are often anchored intorock, concrete or the like, by a combination of adhesives and mechanicalstructures such as an expansion anchor at the distal end of the bolt.Bolts sized ⅝ inch to 1¼ inch in diameter are used in boreholes varyingfrom ¾ inch to 2 inches in diameter. Adhesives are generally formed inplace within the borehole by providing a resin cartridge that includestwo compartments, with a polymerizable (curable) resin in onecompartment, and a hardener or catalyst in another compartment. Aborehole is drilled in the rock, and the cartridge containing thepolymerizable resin and catalyst is inserted into the blind end of theborehole. When a mine roof bolt is inserted into the borehole, thedistal end of the bolt ruptures the package so that the resin andcatalyst are mixed. Rotation of the bolt about its longitudinal axismixes the resin and catalyst. The bolt becomes fixed within the resinupon curing.

In these two component packages, it is critical that the polymerizableresin and the catalyst are maintained separate from each other until thepackage is ruptured during installation of the mine roof bolt. Someresin cartridges include an inner compartment containing catalystsurrounded by an outer compartment containing the polymerizable resin.Other resin cartridges employ a barrier to divide a container into twocompartments with the catalyst and resin on opposing sides of thebarrier. In an aggressive environment, such as an underground mine,resin cartridges are often produced from strong films such aspolyethylene terephthalate, such as Mylar®. Polyethylene terephthalateprovides the desired structural integrity to the resin cartridge, yet ismore costly than other pliable films that may be used in less aggressiveenvironments. Conventional resin cartridges often use polyethyleneterephthalate for the outer compartment as well as the inner compartmentor the barrier, even though these inner structures are not exposed tothe underground mine environment and do not require the structuralintegrity of the outer compartment.

The resin component and the catalyst component may each include fillermaterial in the form of particulate matter. Filler material is used toincrease the volume of the package at a low cost compared to the cost ofadditional reactive components and to control viscosity of thecomponents. The resin cartridges are formulated by balancing the mass ofliquid and solids and the particle size of solids to achieve goodanchorage. If the viscosity or size of the filler is incorrect, the boltmay be difficult to insert into the borehole or the bolt may be insertedinto the borehole, but with poor mixing of the resin and catalyst. Theamount of filler, type of filler and size of the filler is important toobtain proper performance under a variety of applications. Using fillerthat has only very fine particulate matter may result in a product thatdoes not sufficiently shred the tough packaging material. U.S. Pat. No.4,616,050 (incorporated herein by reference) describes the use of fillerwith a minimum particle size of 1 mm and describes appropriate ratios offiller size to the annulus dimension between the bolt and borehole.Excess coarse filler in a resin cartridge can result in a productthrough which it is difficult to properly insert a bolt. In general,bolts that are sized similar to the diameter of the borehole use resincartridges with a smaller particle size than filler that is used inresin cartridges for bolts that are much smaller in diameter than theborehole.

Upon insertion of the bolt into a borehole, the bolt is rotated to shredthe package and enhance mixing until the resin hardens to a degree thatnearly prevents the bolt from being rotated, and the resin is allowed tocure. If the mass of the fillers or liquid resin is incorrect, only aportion of the resin may harden. Since it is essentially difficult todetermine the degree of hardening of the resin in the borehole, it isdesirable that every cartridge have the correct amount of resin, filler,filler particle size, and catalyst and that every cartridge be the sameand be formulated to achieve the optimum performance for eachapplication.

Resin cartridges are produced via a variety of techniques. In general,these techniques involve advancing a web of a film into a tube shapehaving a divider within the tube, thereby producing a partitioned tube.One compartment of the partitioned tube receives the resin compositionand the other compartment of the partitioned tube receives the catalystcomposition. The tube is sealed off at intervals to produce lengths ofthe filled package.

The partitioned package is filled in a packaging machine that receives astream of a curable resin composition into one compartment and a streamof catalyst composition in the other compartment. The resin compositionand the catalyst composition are prepared in separate mixing vessels andare transferred to the packaging machine. The preparation and transferof the resin composition and the catalyst composition has conventionallybeen conducted in batch operations or semi-continuous operations withminimal feedback or process controls.

Accordingly, a need exists for a resin cartridge production system thatoperates on a continuous basis with enhanced process controls foradjusting the compositions of the resin and catalyst components.

SUMMARY OF THE INVENTION

The present invention provides a method and system for producing resincartridges which include components and features that allow forcontinuous production of resin cartridges in partitioned packages withfeedback for adjusting the process conditions to maintain consistentquality of the resin cartridges produced.

The present invention includes a method of producing packages containinga curable resin composition and a catalyst composition that react witheach other when mixed, comprising providing a partitioned tube forreceiving the resin composition and the catalyst composition in separatecompartments; delivering a stream of a resin composition into onecompartment of the tube; delivering a stream of a catalyst compositionin the other compartment of the tube; advancing the partitioned tube andconstricting and sealing the partitioned tube at spaced apart intervalsand severing the sealed tube to produce a package partitioning the resincomposition from the catalyst composition, wherein the method includescontinuously adding solid particulate into the stream of at least one ofthe catalyst composition and the resin composition and mixing the solidparticulate into the stream to produce at least one mixed composition;and controlling the relative amount of solid particulate in the mixedcomposition by continuously determining the mass of solid particulateadded to the mass of the stream. In another embodiment, the presentinvention includes a method of producing a resin cartridge having onecompartment containing a curable resin and another compartmentcontaining a catalyst, the method comprising providing a resin streamfrom a resin feed device; providing a catalyst stream from a catalystfeed device; continuously mixing filler material into the resin streamto produce a resin composition; continuously mixing filler material intothe catalyst stream to produce a catalyst composition; delivering theresin composition and the catalyst composition into the respectivecompartments of a cartridge, wherein the resin and catalyst compositionsare adjusted by altering the composition of at least one of the resinstream and the catalyst stream or by altering the amount of fillermaterial mixed into the resin stream or the catalyst stream. The systemof the present invention includes a dual compartment resin cartridgeproduction system comprising a bulk materials handling subsystem forproviding resin; a resin and filler mixing subsystem for providing aresin composition; a catalyst subsystem for providing a catalystcomposition; a packaging machine subsystem for receiving the resincomposition and the catalyst composition in separate compartments of acartridge; and a computer network comprising controllers for operatingat least one of the subsystems, the controllers providing feedback tothe at least one subsystem for adjusting the subsystem.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of the unit operations and controls for providingresin in the system of the present invention;

FIG. 2 is a schematic of the unit operations and controls for supplyingresin in the system of the present invention;

FIG. 3 is a schematic of the unit operations and controls for mixingparticulates into resin in the system of the present invention;

FIG. 4 is a schematic of the unit operations and controls for feedingcatalyst mixing particulates into the system of the present invention;and

FIG. 5 is a schematic of a computer network for controlling the systemof the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is described with reference to producingtwo-component cartridges containing a resin component and a catalystcomponent for effecting polymerization of the resin upon rupture of thecartridge and mixing of the components, particularly for use inanchoring mine roof bolts. However, this use is exemplary only and notmeant to be limiting. The resin cartridges produced using the presentinvention may be used to anchor other structural compounds. Moreover,the two-component cartridges of the present invention may be used forhousing other components that may or may not be reactive with eachother.

For purposes of the description hereinafter, the terms “upper”, “lower”,“right”, “left”, “vertical”, “horizontal”, “top”, “bottom” andderivatives thereof shall relate to the invention as it is oriented inthe drawing figures. However, it is to be understood that the inventionmay assume various alternative variations and step sequences, exceptwhere expressly specified to the contrary. It is also to be understoodthat the specific devices and processes illustrated in the attacheddrawings, and described in the following specification, are simplyexemplary embodiments of the invention. Hence, specific dimensions andother physical characteristics related to the embodiments disclosedherein are not to be considered as limiting.

FIGS. 1-4 represent the schematic of the system 2 of the presentinvention for delivering a curable resin composition and a catalystcomposition to a packaging machine. The packaging machine is not shownin detail in the drawings and is not limited hereby, except that thepackaging machine is suitable for packaging reactive components into apartitioned package.

In one embodiment of the present invention, varying resin compositionsare used to produce resin cartridges. For example, the resin may includehighly reactive resin that reacts and cures quickly (“fast” resin), lowreactive resin that reacts and cures slowly (“slow” resin) and “medium”speed resin that reacts and cures at intermediate speed. Referring toFIG. 1 (a first portion of the system 2), bulk resin from tanker trucksT (one being shown) is unloaded via resin pumps 4 a, 4 b, 4 c forrespective fast, medium and slow resins via supply lines 6 a, 6 b, 6 cto resin storage tanks 8 a, 8 b, 8 c that accommodate the varying speedresin compositions that include pumps, valves and associated linecontrols for transferring resin. Resin is transferred from tanks 8 a, 8b, 8 c via valve arrangements 10 a, 10 b, 10 c and pumps 12 a, 12 b, 12c through supply lines 14 a, 14 b, 14 c therein to a downstream portionof the system. Three resin storage tanks 8 a, 8 b, 8 c are shown in FIG.1, but this is not meant to be limiting. By incorporating more than oneresin storage tank containing resins with varying cure rates, the system2 of the present invention has flexibility in the ability to produceresin cartridges containing resin which cures at different ratesdepending on the desired end use. However, only one resin composition(stored in one resin storage tank) may be used, or more than threedifferent resin compositions may be used.

FIG. 2 depicts a second portion of the system 2 wherein fast resin,medium resin and slow resin in respective lines 14 a-14 c are providedto resin mix tank A (16 a) and resin mix tank B (16 b) and respectiveresin feed tank A (18 a) and resin feed tank B (18 b). As indicated inFIG. 2, each of the resin mix tanks 16 a, 16 b receives resin from eachof the three resin storage tanks 8 a-8 c via lines 14 a-14 c, therebyproviding a mixture of fast resin, slow resin and medium speed resin.Lines 14 a-14 c are provided with two sets of flow meter/control valvearrangements 20 a, 20 b, 20 c and 22 a, 22 b, 22 c for controlling theamount of resin delivered to resin mix tanks 16 a and 16 b. Tanks 16 aand 16 b are equipped with an agitator 24 for mixing resin and levelcontrolling and sampling ports (not shown) as well as access lids 26 formanually adding material (such as a thickening agent) or removingmaterial (such as for sampling) from tanks 16 a, 16 b. The mixed resinsin tanks 16 a, 16 b are transferred to resin feed tanks 18 a, 18 bequipped with agitators 24, as well as level controllers and samplingports (not shown) and access lids 26. Resin modifiers may be addedmanually to resin mix tanks 16 a, 16 b. Such modifiers include but arenot limited to stabilizers, accelerators (such as dimethyl-p-toluidineor dimethyl aniline), inhibitors (such as quinones), colorants (dyes orpigments). Addition of resin modifiers may also be automated forcontrolled addition to resin mix tanks 16 a, 16 b based on productionneeds or quality control. Resin mix tank 16 b and resin feed tank 18 boperate in parallel to tanks 16 a and 18 a. These parallel resin tankarrangements provide flexibility in the type of resin delivered to apackaging machine. Adjustment of the type of resin produced can be madeon the fly by switching between the parallel tank arrangements. However,only one or more than two sets of a resin mix tank and resin feed tankmay be incorporated in the system of the present invention. Outlet lines28 a, 28 b of resin feed tanks 18 a, 18 b include pumps 30 a and 30 bfor transferring the resin mixture to a third portion of the system 2 asshown in FIG. 3. It will be appreciated that the contents of resin mixtanks A and B (16 a, 16 b) may be operated in a batch mode. Uponachieving the desired composition of resin in mixtures 16 a, 16 b, theresin is transferred to resin feed tanks 18 a, 18 b via pumps 27 a, 27b. Resin feed tanks 18 a, 18 b serve as starting points of a continuousprocess of supplying resin to the packaging machines PM-1, PM-2.

Referring to FIG. 3, the resin mixture is combined with a filler of aparticulate matter to provide a resin composition. The relative amountof particulate matter that is added to the resin as a filler materialaffects the cost and performance of the final product. A high relativeamount of resin increases the cost of the resulting product and candecrease the performance due to shrinkage and low stiffness of the resinupon curing. Insufficient resin or a high relative amount of particulatematter results in a product with excessive viscosity, which makes itdifficult to properly insert the bolt or results in poor mixing. Theparticulate matter may include fillers of varying sizes such as 500 μmor less (fine filler) to 6000 μm (coarse filler). The balance of theamount of coarse and fine fillers also affects the product performance.For a given filler, there generally is an optimal ratio of fine fillerto coarse filler that produces an acceptable viscosity in the resincomposition. For small boreholes (e.g., 1 inch) with a smaller annulusbetween a bolt and the borehole wall, it may be advantageous to use ahigher proportion of fine filler than in larger boreholes. Theproportional amounts of fine filler and coarse filler may be selected asdisclosed in U.S. Pat. No. 5,993,116 to Paxton et al., incorporatedherein by reference. In order to accurately control the amount of coarseand fine fillers added to a resin cartridge, the present inventionemploys mass meters for determining the amount of filler added to theresin. An insufficient amount of filler used can negatively impact resinstrength, stiffness and shrinkage, which may result in poor bonding androof support.

The resin mixture from line 28 a is metered through mass flow meter 29 aand supplied to an in-line mixer 32 a. Particulate matter, such aslimestone, sandstone or shale, is also supplied to the in-line mixer 32a, via lines 34 a, 36 a to the in-line mixer 32 a. Suitable in-linemixers are available from Palmer Manufacturing of Springfield, Ohio.Coarse particulates are provided via line 34 a, and fine particulatesare added via line 36 a into a hopper 38 a that feeds to mixer 32 a. Therespective amounts of coarse and fine particulate matter that are addedto the in-line mixer 32 a are controlled via mass meters 40 a, 42 a onrespective lines 34 a, 36 a for the coarse particulates and the fineparticulates. In one embodiment, the mass meters 40 a, 42 a are loss andweight feeders, which weigh the particulates on a belt that feeds tolines 34 a, 34 b. The resulting resin composition containing particulatematter is transferred to a resin hold tank 44 a. The system 2 includesfeedback controls for monitoring and adjusting the amount of particulatematter added to the resin composition. In-line mass meters 40 a and 42 aprovide accurate and instantaneous information on the amount ofparticulate matter added to the resin composition. For example, if theviscosity of the resin composition is excessive at a downstream portionof the system 2, a signal may be automatically or manually generated toreduce the amount of particulate matter added and/or to increase theamount of resin added, that change being monitored by mass flow meters29 a, 29 b and/or mass meters 40 a, 42 a.

The resin composition is remixed via an in-line mixer 46 a prior todelivery to packaging machine PM-1. Mixer 46 a includes a mixing chamberand a set of parallel twin screws for advancing the composition towardthe packaging machine, such as a Moyno 2000 HS System available fromMoyno, Inc. of Springfield, Ohio. The twin screws provide post-mixing tothe compositions and scrape material off the sides of the mixingchamber. The twin screw in-line mixer 46 a of the present invention hasintermeshing blades and a combined mixing diameter of both screws thatis equal to or greater than the width dimension of the chamber. The twinscrews operate at a speed that pumps about 10 times more materialthrough the chamber than is delivered thereto and at least 2 to 10,000times or 50 to 1,000 times more product per minute than the packagingmachines use. This forces a substantial portion of, such as 50 to 1,000times, the amount of resin composition backward through an upper portionof the mixing chamber. The backward flowing resin composition is foldedback into the new material being added and is remixed, thereby ensuringthat all product exiting the twin screws is uniform and is substantiallyblended with new material. This remixing feature within mixer 46 aproduces a uniform product with minimal or no variance from cartridge tocartridge or between cases of cartridges. The twin screws exert asubstantial amount of work on the product, producing heat that reducesthe viscosity of the resin composition. The amount of work exerted onthe product may be enough to produce a 5° C. temperature rise, or a 5 to20° C., or no more than 50° C. rise in the product exiting the twinscrews.

The twin screw resin mixer 46 a is configured to receive a compositionhaving 50% filler and 50% resin or up to 100% filler (no liquid) withoutplugging or overloading for at least 1 minute or at least 10 minutes. Inthe event of an interruption in the supply of liquid (resin) feed, themixer can process dry material thereby avoiding downtime associated withprior resin mixing systems. Prior resin mixing systems cannot processdry material and with loss of liquid feed for just a few seconds,results in failure of the mixer drive shaft, motor, baffles and requireslong downtime to repair.

In the present invention, in-line mixer 32 a and twin screw mixer 46 aensure that essentially all of the filler material added to the resinwill be received downstream. By accurately measuring the mass ofparticulates added via mass meters, the final composition of the resincomposition can be accurately obtained.

A level controller within the mixing chamber of twin screw mixer 46 a,such as a radar level controller, provides feedback for increasing therate of delivery of the resin composition to the mixer 46 a, starting orstopping the in-line mixers 32 a, 32 b. The outlet of mixer 46 a istransferred via resin tank booster pump 48 a to the packaging machinePM-1 via line 50 a and may also be returned via line 52 a to the resinhold tank 44 a. Likewise, in a parallel operation, resin from line 28 b,monitored via mass flow meter 29 b, is mixed in mixer 32 b, with coarseand fine particulate matter from lines 34 b, 36 b provided via massmeters 40 b, 42 b and hopper 38 b, held in a resin hold tank 44 b,post-mixed via twin screw mixer 46 b with delivery to packaging machinePM-2 via line 50 b and to resin hold tank 44 b via line 52 b and pump 48b.

In one embodiment, density flow meters 49 a, 49 b are provided onrespective lines 50 a, 50 b. Density flow meters 49 a, 49 b provide dataon mass flow rate, density and optional temperature. The density of theresin composition exiting resin composition hold tanks 44 a, 44 b can beused to determine the relative amounts of resin and filler therein. Thedensity of the resin composition is a function of the relative amountsof the components thereof. For example, the density of resin is low(e.g., about 1-1.4 g/ml), and the density of the filler is higher (e.g.,about 2.7-3.0 g/ml). The relative amounts of resin and filler may bedetermined based on their individual densities and the density of theresin composition. Adjustment of the amounts of resin and/or filleradded to the resin composition upstream may be made to achieve a desireddensity of the resin composition determined by density meters 49 a, 49b.

Similarly, FIG. 4 depicts a schematic of the production of catalystcomposition for delivery to the packaging machine. A catalyst material(such as benzoyl peroxide in paste form) is provided from a drum D orthe like via line 54 and pump 56 and transferred to a catalyst mix tank58 equipped with an agitator 24 and access lid 26. Water is added vialine 62 for diluting the catalyst. In one embodiment, a thickening agentis manually added to catalyst mix tank 58, containing water via accesslid 26 until a desired viscosity of material within the catalyst mixtank is achieved. The catalyst is added to tank 58 via line 54, and thecontents of tank 58 are checked for catalyst concentration and adjustedas necessary. After mixing, the diluted catalyst composition istransferred via line 64 and pump 66 to a catalyst feed tank 68 equippedwith an agitator 24 and access lid 26 for holding the catalystcomposition. An outlet line 72 of the catalyst feed tank 68 includes apump 74 for transferring the catalyst composition to catalyst in-linemixer 76, as shown in FIG. 4. In this manner, catalyst mix tank 58 isoperated in a batch mode and catalyst feed tank 68 serves as a startingpoint of a continuous process for supplying catalyst to the packagingmachines PM-1 and PM-2. Coarse particulate matter and fine particulatematter are supplied from respective feed lines 78 and 80 with massmeters 82 and 84 to hopper 86. The amount of coarse and fine particulatematter added to hopper 86 is controlled via mass meters 82, 84. Thesystem 2 includes feedback controls for monitoring the amount ofparticulate that has been added to the catalyst composition. Thecatalyst composition with particulate matter is transferred to a holdtank 88. The catalyst composition with particulates is remixed viain-line mixer 90 for final mixing of the catalyst composition prior totransfer to the packaging machines PM-1 and PM-2. In-line mixer 90 iscomparable to in-line mixers 46 a, 46 b in its structure and operation.Outlet of mixer 90 is transferred through line 94 via mixed catalystpump 92 with optional recycling via line 96.

Packaging machines PM-1 and PM-2 receive resin composition from resincomposition hold tanks 44 a and 44 b, respectively. Catalyst compositionis delivered to both packaging machines PM-1 and PM-2 from catalystcomposition hold tank 88. A suitable packaging machine is described inU.S. Pat. No. 3,889,446, incorporated herein by reference. Generally,such packaging machines produce resin cartridges by forming a web ofpliable film into an advancing first tube with the edges of the tubeoverlapping each other. A second tube is formed therein by advancinganother film into the first tube, thereby creating a second tube withinthe first tube, i.e., one compartment within another compartment.Alternatively, an edge of the first tube may span the diameter of thetube to create side-by-side compartments. These are only examples ofpackaging techniques and are not meant to be limiting. Each of thepackaging machines PM-1 and PM-2 include a resin packaging pump and acatalyst packaging pump (not shown) for delivering the resin andcatalyst compositions into the two compartments of the packaging,referred to hereinafter as first and second resin packaging pumps andfirst and second catalyst packaging pumps. The packaging advances as itis filled until a pre-determined length (such as two to three feet) isfilled. The packaging machine seals the compartments together and cutsthe length of filled packaging at the seal, yielding a cartridge withone compartment containing the resin composition and another compartmentcontaining the catalyst composition.

Referring to FIG. 5, the system of the present invention includes anetwork 102 for controlling the components depicted in FIGS. 1-4 via aremote station. Network 102 includes numerous components in mutualcommunication via switch or hub 104 with which at least one controlterminal 106 communicates. In one embodiment, as detailed below, thenetwork 102 controls the production of resin cartridges according tosubsystems such as bulk material handling, resin mixing, catalystmixing, packaging machine operation, pumping of resin and catalyst tothe packaging machines, and cutting and handling of resin cartridges.For at least these subsystems of the system 2, network 102 includesinput/output devices (e.g. touch screens) and programmable logiccontrollers (PLCs). Touch screen 108 and PLC 110 are programmed forautomating and controlling the components of the bulk components of theresin and filler, such as the components shown in FIG. 1. Touch screen112 and PLC 114 for mix system A (i.e., the components 16 a-52 a ofFIGS. 2 and 3) are programmed for automating and controlling delivery ofresin to the packaging machine PM-1, including at least the amount ofresins (e.g., the relative concentration of slow, medium and fastresins) and the amount of modifiers added to resin mix tank 16 a,controlling transfer pump 27 a, maintaining the level in resin feed tank18 a, monitoring output of resin mass flow meter 29 a, and controllingpump 30 a. Delivery of filler is also automated and controlled by touchscreen 112 and PLC 114 in monitoring output of mass meters 40 a and 42a, controlling operation of mixer 32 a, maintaining the level in resincomposition hold tank 44 a, and controlling operation of mixer 46 a andbooster pump 48 a. Likewise, components 16 b-52 b (mix system B) ofFIGS. 2 and 3 are automated and controlled via touch screen 116 and PLC118.

Components 54-92 (catalyst system) are automated and controlled viatouch screen 120 and PLC 122 in at least controlling the amount ofcatalyst and solvent added to catalyst mix tank 58, controlling transferpump 66, maintaining the level in catalyst feed tank 68, controllingpump 74, monitoring output of mass meters 84 and 82, controllingoperation of mixer 76, maintaining the level in catalyst compositionhold tank 88, and controlling operation of mixer 90 and pump 92.

The packaging machines PM-1 and PM-2 are controlled via touch screen 124and PLC 126 and via touch screen 128 and PLC 130, respectively. Touchscreen 132 and PLC 134 control the first resin packaging pump ofpackaging machine PM-1. Touch screen 136 and PLC 138 control the firstcatalyst pump of packaging machine PM-1. Second resin packaging pump andsecond catalyst packaging pump of machine PM-2 are likewise controlledvia respective touch screens 140, 144 and PLCs 142, 146. Touch screen148 and PLC 150 control cutting of packages by packaging machines PM-1,PM-2 (i.e., the location of cuts), tally the production and calculateproduction quantities remaining to fulfill a production need.

Each PLC may operate independently of the other PLCs, and communicateswithin the network 102 to receive control instructions from the network102. Thus, each PLC can be controlled, changed and monitored locally orremote from the network 102 via terminal 106, such as in a productionplanning facility. If a problem develops in one subsystem, the othersubsystems automatically take corrective actions or shut down the system2. When a product change is made (e.g., to produce a different resincomposition), the resin mix subsystem, catalyst mix subsystem andpackaging machines are automatically reconfigured to accommodate the newproduct. Such product changes may be made locally or remotely viaterminal 106. Terminal 106 also records and archives processinformation, including any alarms. This historical data may be reviewedand is available for troubleshooting on-site or remotely.

The PLCs 110, 114, 118, 122, 126, 130, 134, 138, 142, 146 and 150monitor their respective portions of system 2 and make adjustments tomaintain desired set points. The desired set points may be based oncompositional requirements (e.g., relative amounts of resin and filler)or property requirements (e.g., density of resin composition fed to thepackaging machine) or both. For example, if the output of mass meter 40a indicates that the amount of fine filler being added to mixer 32 a islower than a predetermined set point, PLC 114 will increase the feedrate for fine filler until the set point is reached. Alternatively, ifthe output of density flow meter 49 a indicates that the resincomposition contains a lower proportion of filler than desired, PLC 114will increase the feed rate for fine filler or coarse filler or both toachieve a predetermined set point for the density of the resincomposition. These are examples of how the PLCs may be used to controlthe process and are not intended to be limiting. Alternatively, or inaddition thereto, the system 2 may include components (not shown) fordetermining viscosity of the compositions, such as the mixed resin, thecatalyst, the resin composition containing filler, or the catalystcomposition. Viscosity measurements may also be made off-line fromsamples.

It will be readily appreciated by those skilled in the art thatmodifications may be made to the invention without departing from theconcepts disclosed in the foregoing description. Such modifications areto be considered as included within the following claims unless theclaims, by their language, expressly state otherwise. Accordingly, theparticular embodiments described in detail herein are illustrative onlyand are not limiting to the scope of the invention which is to be giventhe full breadth of the appended claims and any and all equivalentsthereof.

1. A method of producing a resin cartridge having one compartmentcontaining a curable resin and another compartment containing acatalyst, the method comprising: providing a resin stream from a resinfeed device; providing a catalyst stream from a catalyst feed device;continuously mixing filler material into the resin stream to produce aresin composition; continuously mixing filler material into the catalyststream to produce a catalyst composition; delivering the resincomposition and the catalyst composition into the respectivecompartments of a cartridge, wherein the resin and catalyst compositionsare adjusted by altering the composition of at least one of the resinstream and the catalyst stream or by altering the amount of fillermaterial mixed into the resin stream or the catalyst stream.
 2. Themethod of claim 1, wherein the resin stream comprises a plurality ofresin components and the composition of the resin stream is adjusted byaltering the relative amounts of the resin components delivered to aresin stream feed device.
 3. The method of claim 1, wherein the catalystcomposition comprises a catalyst component and a solvent and thecomposition of the catalyst stream is adjusted by altering the relativeamounts of catalyst and solvent delivered to a catalyst stream feeddevice.
 4. The method of claim 1, wherein the amount of filler materialmixed into the resin stream or the catalyst stream is altered bycontrolling the mass of filler material added thereto to achieve adesired viscosity.
 5. The method of claim 4, further comprisingdetermining the density of the resin composition, determining therelative amounts of resin and filler material in the resin compositionbased on the density of the resin composition, wherein the step ofadjusting the resin composition comprises altering the relative amountsof resin and filler material to achieve a desired density of the resincomposition.
 6. The method of claim 1, wherein adjustments to thecomposition of the resin stream or the catalyst stream or to the amountof filler material added thereto are performed by a programmable logiccontroller.
 7. The method of claim 6, wherein the adjustments are madeto maintain the composition of the resin composition or the catalystcomposition within predetermined limits or to maintain a property of theresin composition or the catalyst composition.
 8. A dual compartmentresin cartridge production system comprising: a bulk materials handlingsubsystem for providing resin; a resin and filler mixing subsystem forproviding a resin composition; a catalyst subsystem for providing acatalyst composition; a packaging machine subsystem for receiving theresin composition and the catalyst composition in separate compartmentsof a cartridge; and a computer network comprising controllers foroperating at least one of said subsystems, said controllers providingfeedback to said at least one subsystem for adjusting said subsystem. 9.The system of claim 8, wherein said controllers compare the constituentsof at least one of the resin composition and the catalyst composition toa predetermined set point and adjust the compared compositions as neededto achieve the set point.
 10. The system of claim 8, wherein saidcontrollers compare a property of at least one of the resin compositionand the catalyst composition to a predetermined set point and adjust atleast one of the compositions to achieve the set point.
 11. The systemof claim 8, wherein said network comprises a remote terminal foraccessing said controllers.
 12. The system of claim 8, wherein saidnetwork further comprises an input/output device for each saidsubsystem, said input/output device providing output regarding saidsubsystem and accepting input for adjusting said subsystem.
 13. Themethod of claim 1 wherein the method is performed using the system ofclaim 8.